Methods for additive manufacturing

ABSTRACT

A method of additively manufacturing an object comprises applying a resin in a first non-rigid uncured state to elongate fibers to create a feedstock line, transforming the resin of the feedstock line from the first non-rigid uncured state to a rigid uncured state, introducing the feedstock line into a delivery guide with the resin of the feedstock line in the rigid uncured state, transforming the resin of the feedstock line from the rigid uncured state to a second non-rigid uncured state as the feedstock line passes through the delivery guide or as the feedstock line exits the delivery guide, depositing the feedstock line along a print path, and at least partially curing the resin of the feedstock line after the feedstock line is deposited by the delivery guide along the print path.

FIELD

The present disclosure relates to additive manufacturing.

BACKGROUND

An additive manufacturing process may include dispensing or extruding afeedstock material from a print head, or nozzle, that is capable ofmoving in three dimensions under computer control to manufacture a part.Depending on the properties of the feedstock material, its advancementthrough the print head may be difficult or result in undesirableeffects. For example, when the feedstock material is or includes aglutinous material, the feedstock material may gum-up, clog, orotherwise foul the print head. As another example, when the feedstockmaterial includes elongate carbon or other fibers, the fibers may kink,break, or otherwise buckle and become damaged or clog the print head. Asyet another example, when the feedstock material is or includes anuncured or partially cured, curable resin, the resin may undesirablygradually cure inside the print head to progressively clog the printhead and partially or completely obstruct the operative advancement ofthe feedstock material through the print head.

SUMMARY

Accordingly, apparatuses and methods, intended to address at least theabove-identified concerns, would find utility.

The following is a non-exhaustive list of examples, which may or may notbe claimed, of the subject matter according to the invention.

One example of the subject matter according to the invention relates toa system for additively manufacturing an object. The system comprises afiber supply, a resin supply, a rigidizing mechanism, a delivery guide,a feed mechanism, a de-rigidizing mechanism, and a curing mechanism. Thefiber supply is configured to dispense the elongate fibers. The resinsupply is configured to apply a resin to the elongate fibers, dispensedfrom the fiber supply, to create a feedstock line. The feedstock linecomprises the elongate fibers, at least partially encapsulated in theresin, which is in a first non-rigid uncured state. The rigidizingmechanism is to receive the feedstock line with the resin in the firstnon-rigid uncured state. The rigidizing mechanism is configured totransform the resin of the feedstock line from the first non-rigiduncured state to a rigid uncured state. The feedstock line and the resinare more rigid when the resin is in the rigid uncured state than whenthe resin is in the first non-rigid uncured state. The delivery guide isto receive the feedstock line from the rigidizing mechanism with theresin in the rigid uncured state. The delivery guide is configured todeposit the feedstock line along a print path. The feed mechanism isconfigured to feed the feedstock line through the delivery guide. Thede-rigidizing mechanism is configured to transform the resin of thefeedstock line, as the feedstock line passes through the delivery guideor as the feedstock line exits the delivery guide, from the rigiduncured state to a second non-rigid uncured state, so that, before thefeedstock line is deposited along the print path by the delivery guide,the resin of the feedstock line, exiting the delivery guide, is in thesecond non-rigid uncured state. The feedstock line and the resin areless rigid when the resin is in the second non-rigid uncured state thanwhen the resin is in the rigid uncured state. The curing mechanism isconfigured to transform the resin of the feedstock line, deposited bythe delivery guide along the print path, from the second non-rigiduncured state to an at least partially cured state.

The system therefore may be used to manufacture the object from a fiberreinforced composite material that is created from the resin and theelongate fibers while the object is being manufactured. Moreover, thesystem may be used to manufacture the object with the elongate fibersbeing oriented in desired and/or predetermined orientations throughoutthe object, such as to define desired properties of the object. Inaddition, because the resin is uncured when applied to the elongatefibers to create the feedstock line, the first non-rigid uncured stateof the feedstock line comprises the resin in a viscous condition. Ifpermitted to remain in such a viscous, tacky, or sticky condition, theresin of the feedstock line would be difficult to handle by the system,and the feed mechanism and the delivery guide thereof, for example,gumming up or otherwise soiling component parts of the system. Moreover,if the resin were in such a viscous state, the elongate fibers may becaused to buckle at the inlet to or within the delivery guide.Accordingly, the rigidizing mechanism transforms the feedstock line fromthe first non-rigid uncured state to the rigid uncured state so that thefeed mechanism can advance the feedstock line into the delivery guidewithout soiling or damaging the feed mechanism, and without the elongatefibers buckling, breaking, or otherwise becoming damaged. Moreover,because the feedstock line is then in the rigid uncured state, it willeasily be advanced through the delivery guide for ultimate depositingalong the print path to manufacture the object. However, the feedstockline in its rigid uncured state is too rigid for deposition along theprint path in three-dimensions. Accordingly, the de-rigidizing mechanismis provided to transform the feedstock line from the rigid uncured stateto a sufficiently non-rigid uncured state—the second non-rigid uncuredstate—for ultimate deposition along the print path. The de-rigidizingmechanism may de-rigidize the feedstock line either as it is passingthrough the delivery guide or as the feedstock line exits the deliveryguide, depending on the configuration of the de-rigidizing mechanism anddepending on the properties of the feedstock line in the secondnon-rigid uncured state. Finally, the curing mechanism transforms theresin from the second non-rigid uncured state to the at least partiallycured state, to at least partially cure the object while it is beingmanufactured, or in situ.

Another example of the subject matter according to the invention relatesto a method of additively manufacturing an object. The method comprisesapplying a resin in a first non-rigid uncured state to elongate fibersto create a feedstock line. The feedstock line comprises the elongatefibers at least partially encapsulated in the resin. The method alsocomprises transforming the resin of the feedstock line from the firstnon-rigid uncured state to a rigid uncured state. The feedstock line andthe resin are more rigid when the resin is in the rigid uncured statethan when the resin is in the first non-rigid uncured state. The methodfurther comprises introducing the feedstock line into a delivery guidewith the resin of the feedstock line in the rigid uncured state. Themethod additionally comprises transforming the resin of the feedstockline from the rigid uncured state to a second non-rigid uncured state asthe feedstock line passes through the delivery guide or as the feedstockline exits the delivery guide. The feedstock line and the resin are lessrigid when the resin is in the second non-rigid uncured state than whenthe resin is in the rigid uncured state. The method also comprisesdepositing the feedstock line along a print path, with the resin of thefeedstock line in the second non-rigid uncured state, using the deliveryguide. The method further comprises at least partially curing the resinof the feedstock line after the feedstock line is deposited by thedelivery guide along the print path.

The method therefore may implemented to manufacture the object from afiber reinforced composite material that is created from the resin andthe elongate fibers while the object is being manufactured. Moreover,the method may be implemented to manufacture the object with theelongate fibers being oriented in desired and/or predeterminedorientations throughout the object, such as to define desired propertiesof the object. In addition, because the resin is uncured when applied tothe elongate fibers to create the feedstock line, the first non-rigiduncured state of the feedstock line comprises the resin in a viscouscondition. If permitted to remain in such a viscous, tacky, or stickycondition, the resin of the feedstock line would be difficult tointroduce into the delivery guide, for example, potentially gumming upthe delivery guide or buckling, kinking, or even breaking the elongatefibers. Accordingly, transforming the resin to the rigid uncured statefacilitates the introduction of the feedstock line into and the passageof the feedstock line through the delivery guide, without the elongatefibers buckling, breaking, or otherwise becoming damaged, and withoutthe resin soiling an associated system. Subsequently transforming theresin from the rigid uncured state to the second non-rigid uncured stateas the feedstock line passes through the delivery guide or as thefeedstock line exits the delivery guide results in the feedstock linebeing sufficiently flexible to operatively be deposited in threedimensions by the delivery guide to additively manufacture the object.Depending on the properties of the feedstock line, in someimplementations of the method, it may be beneficial to transform thefeedstock line to the second non-rigid cured state as it passes throughthe delivery guide. In other implementations of the method, it may bebeneficial to transform the feedstock line to the second non-rigiduncured state as it exits the delivery guide. Finally, at leastpartially curing the resin from the second non-rigid uncured state tothe at least partially cured state, enables curing of the object as itis being manufactured, or in situ.

BRIEF DESCRIPTION OF THE DRAWINGS

Having thus described one or more examples of the invention in generalterms, reference will now be made to the accompanying drawings, whichare not necessarily drawn to scale, and wherein like referencecharacters designate the same or similar parts throughout the severalviews, and wherein:

FIG. 1 is a block diagram of a system for additively manufacturing anobject, according to one or more examples of the present disclosure;

FIG. 2 is a schematic representation of the system of FIG. 1, accordingto one or more examples of the present disclosure;

FIG. 3 is a flow diagram of a method of additively manufacturing anobject, according to one or more examples of the present disclosure;

FIG. 4 is a flow diagram of aircraft production and service methodology;and

FIG. 5 is a schematic illustration of an aircraft.

DESCRIPTION

In FIG. 1, referred to above, solid lines, if any, connecting variouselements and/or components may represent mechanical, electrical, fluid,optical, electromagnetic and other couplings and/or combinationsthereof. As used herein, “coupled” means associated directly as well asindirectly. For example, a member A may be directly associated with amember B, or may be indirectly associated therewith, e.g., via anothermember C. It will be understood that not all relationships among thevarious disclosed elements are necessarily represented. Accordingly,couplings other than those depicted in the block diagrams may alsoexist. Dashed lines, if any, connecting blocks designating the variouselements and/or components represent couplings similar in function andpurpose to those represented by solid lines; however, couplingsrepresented by the dashed lines may either be selectively provided ormay relate to alternative examples of the present disclosure. Likewise,elements and/or components, if any, represented with dashed lines,indicate alternative examples of the present disclosure. One or moreelements shown in solid and/or dashed lines may be omitted from aparticular example without departing from the scope of the presentdisclosure. Environmental elements, if any, are represented with dottedlines. Virtual (imaginary) elements may also be shown for clarity. Thoseskilled in the art will appreciate that some of the features illustratedin FIG. 1 may be combined in various ways without the need to includeother features described in FIG. 1, other drawing figures, and/or theaccompanying disclosure, even though such combination or combinationsare not explicitly illustrated herein. Similarly, additional featuresnot limited to the examples presented, may be combined with some or allof the features shown and described herein.

In FIGS. 3 and 4, referred to above, the blocks may represent operationsand/or portions thereof and lines connecting the various blocks do notimply any particular order or dependency of the operations or portionsthereof. Blocks represented by dashed lines indicate alternativeoperations and/or portions thereof. Dashed lines, if any, connecting thevarious blocks represent alternative dependencies of the operations orportions thereof. It will be understood that not all dependencies amongthe various disclosed operations are necessarily represented. FIGS. 3and 4 and the accompanying disclosure describing the operations of themethod(s) set forth herein should not be interpreted as necessarilydetermining a sequence in which the operations are to be performed.Rather, although one illustrative order is indicated, it is to beunderstood that the sequence of the operations may be modified whenappropriate. Accordingly, certain operations may be performed in adifferent order or simultaneously. Additionally, those skilled in theart will appreciate that not all operations described need be performed.

In the following description, numerous specific details are set forth toprovide a thorough understanding of the disclosed concepts, which may bepracticed without some or all of these particulars. In other instances,details of known devices and/or processes have been omitted to avoidunnecessarily obscuring the disclosure. While some concepts will bedescribed in conjunction with specific examples, it will be understoodthat these examples are not intended to be limiting.

Unless otherwise indicated, the terms “first,” “second,” etc. are usedherein merely as labels, and are not intended to impose ordinal,positional, or hierarchical requirements on the items to which theseterms refer. Moreover, reference to, e.g., a “second” item does notrequire or preclude the existence of, e.g., a “first” or lower-numbereditem, and/or, e.g., a “third” or higher-numbered item. Reference hereinto “one example” means that one or more feature, structure, orcharacteristic described in connection with the example is included inat least one implementation. The phrase “one example” in various placesin the specification may or may not be referring to the same example.

As used herein, a system, apparatus, structure, article, element,component, or hardware “configured to” perform a specified function isindeed capable of performing the specified function without anyalteration, rather than merely having potential to perform the specifiedfunction after further modification. In other words, the system,apparatus, structure, article, element, component, or hardware“configured to” perform a specified function is specifically selected,created, implemented, utilized, programmed, and/or designed for thepurpose of performing the specified function. As used herein,“configured to” denotes existing characteristics of a system, apparatus,structure, article, element, component, or hardware which enable thesystem, apparatus, structure, article, element, component, or hardwareto perform the specified function without further modification. Forpurposes of this disclosure, a system, apparatus, structure, article,element, component, or hardware described as being “configured to”perform a particular function may additionally or alternatively bedescribed as being “adapted to” and/or as being “operative to” performthat function.

Illustrative, non-exhaustive examples, which may or may not be claimed,of the subject matter according the present disclosure are providedbelow.

Referring generally to FIG. 1 and particularly to FIG. 2, system 100 foradditively manufacturing object 102 is disclosed. System 100 comprisesfiber supply 122, resin supply 124, rigidizing mechanism 112, deliveryguide 116, feed mechanism 126, de-rigidizing mechanism 118, and curingmechanism 120. Fiber supply 122 is configured to dispense elongatefibers 108. Resin supply 124 is configured to apply resin 110 toelongate fibers 108, dispensed from fiber supply 122, to createfeedstock line 106. Feedstock line 106 comprises elongate fibers 108, atleast partially encapsulated in resin 110, which is in a first non-rigiduncured state. Rigidizing mechanism 112 is to receive feedstock line 106with resin 110 in the first non-rigid uncured state. Rigidizingmechanism 112 is configured to transform resin 110 of feedstock line 106from the first non-rigid uncured state to a rigid uncured state.Feedstock line 106 and resin 110 are more rigid when resin 110 is in therigid uncured state than when resin 110 is in the first non-rigiduncured state. Delivery guide 116 is to receive feedstock line 106 fromrigidizing mechanism 112 with resin 110 in the rigid uncured state.Delivery guide 116 is configured to deposit feedstock line 106 alongprint path 114. Feed mechanism 126 is configured to feed feedstock line106 through delivery guide 116. De-rigidizing mechanism 118 isconfigured to transform resin 110 of feedstock line 106, as feedstockline 106 passes through delivery guide 116 or as feedstock line 106exits delivery guide 116, from the rigid uncured state to a secondnon-rigid uncured state, so that, before feedstock line 106 is depositedalong print path 114 by delivery guide 116, resin 110 of feedstock line106, exiting delivery guide 116, is in the second non-rigid uncuredstate. Feedstock line 106 and resin 110 are less rigid when resin 110 isin the second non-rigid uncured state than when resin 110 is in therigid uncured state. Curing mechanism 120 is configured to transformresin 110 of feedstock line 106, deposited by delivery guide 116 alongprint path 114, from the second non-rigid uncured state to an at leastpartially cured state. The preceding subject matter of this paragraphcharacterizes example 1 of the present disclosure.

System 100 therefore may be used to manufacture object 102 from a fiberreinforced composite material that is created from resin 110 andelongate fibers 108 while object 102 is being manufactured. Moreover,system 100 may be used to manufacture object 102 with elongate fibers108 being oriented in desired and/or predetermined orientationsthroughout object 102, such as to define desired properties of object102. In addition, because resin 110 is uncured when applied to elongatefibers 108 to create feedstock line 106, the first non-rigid uncuredstate of feedstock line 106 comprises resin 110 in a viscous condition.If permitted to remain in such a viscous, tacky, or sticky condition,resin 110 of feedstock line 106 would be difficult to handle by system100, and feed mechanism 126 and delivery guide 116 thereof, for example,gumming up or otherwise soiling component parts of system 100. Moreover,if resin 110 were in such a viscous state, elongate fibers 108 may becaused to buckle at the inlet to or within delivery guide 116.Accordingly, rigidizing mechanism 112 transforms feedstock line 106 fromthe first non-rigid uncured state to the rigid uncured state so thatfeed mechanism 126 can advance feedstock line 106 into delivery guide116 without soiling or damaging feed mechanism 126, and without elongatefibers 108 buckling, breaking, or otherwise becoming damaged. Moreover,because feedstock line 106 is then in the rigid uncured state, it willeasily be advanced through delivery guide 116 for ultimate depositingalong print path 114 to manufacture object 102. However, feedstock line106 in its rigid uncured state is too rigid for deposition along printpath 114 in three-dimensions. Accordingly, de-rigidizing mechanism 118is provided to transform feedstock line 106 from the rigid uncured stateto a sufficiently non-rigid uncured state—the second non-rigid uncuredstate—for ultimate deposition along print path 114. Moreover,de-rigidizing mechanism 118 ensures appropriate wetting, or adhesion,between two adjacent layers of feedstock line 106, when a length offeedstock line 106 is being deposited against a prior-deposited lengthof feedstock line 106. De-rigidizing mechanism 118 may de-rigidizefeedstock line 106 either as it is passing through delivery guide 116 oras feedstock line 106 exits delivery guide 116, depending on theconfiguration of de-rigidizing mechanism 118 and depending on theproperties of feedstock line 106 in the second non-rigid uncured state.Finally, curing mechanism 120 transforms resin 110 from the secondnon-rigid uncured state to the at least partially cured state, to atleast partially cure object 102 while it is being manufactured, or insitu.

Some examples of system 100 additionally or alternatively may bedescribed as 3-D printers. Elongate fibers 108 may take any suitableform and be constructed of any suitable material depending on desiredproperties of object 102 to be manufactured by system 100. In oneexample, elongate fibers 108 include, but are not limited, to carbonfibers, glass fibers, synthetic organic fibers, aramid fibers, naturalfibers, wood fibers, boron fibers, silicon-carbide fibers, opticalfibers, fiber bundles, fiber tows, fiber weaves, fiber braids, wires,metal wires, conductive wires, and wire bundles. Feedstock line 106 maybe created from a single configuration, or type, of elongate fibers 108or may be created from more than one configuration, or type, of elongatefibers 108. By “elongate,” it is meant that elongate fibers 108 aregenerally continuous in nature along feedstock line 106 as it is beingcreated, as opposed to, for example, use of chopped-fiber segments. Thatsaid, elongate fibers 108 may comprise discontinuous segments of fibersthat are bundled, woven, braided, or otherwise combined, and still beconsidered generally continuous in nature along feedstock line 106.Elongate fibers 108 have a length that is significantly longer than adimension (e.g., diameter or width) that is transverse, orperpendicular, to its length. As an illustrative, non-exclusive example,elongate fibers 108 may have a length that is at least 100, at least1000, at least 10000, at least 100000, or at least 1000000 times greaterthan their diameter or width.

Resin 110 may take any suitable form depending on desired properties ofobject 102 and depending on the functionality of system 100 and curingmechanism 120. In some examples, resin 110 may comprise a photopolymerresin that is configured to be cured by selective application of light.In other examples, resin 110 may comprise a thermoset resin that isconfigured to be cured by selective application of heat or radiation.Other types of resin 110 also may be used and incorporated into system100.

Referring generally to FIG. 1 and particularly to FIG. 2, feedstock line106 in the first non-rigid uncured state has a shear modulus less thanor equal to 0.1 GPa. Feedstock line 106 in the rigid uncured state has ashear modulus greater than 0.1 GPa. Feedstock line 106 in the secondnon-rigid uncured state has a shear modulus less than or equal to 0.1GPa. The preceding subject matter of this paragraph characterizesexample 2 of the present disclosure, wherein example 2 also includes thesubject matter according to example 1, above.

With 0.1 GPa as a threshold shear modulus, or rigidity, feedstock line106, when rigidized by rigidizing mechanism 112, is sufficiently rigidto be advanced by feed mechanism 126 into and through delivery guide116. Moreover, by de-rigidizing feedstock line 106 below a shear modulusof 0.1 GPa, feedstock line 106 may be deposited along a circuitous printpath, e.g., print path 114 with curves in two or three dimensions.However, other threshold values of shear modulus may be utilized, suchas based on the stiffness of elongate fibers 108, the number of elongatefibers 108 in a corresponding tow, a shape of feedstock line 106, adiameter of feedstock line 106, properties of resin 110, etc.

Referring generally to FIG. 1 and particularly to FIG. 2, rigidizingmechanism 112 is configured to withdraw heat from resin 110 of feedstockline 106 in the first non-rigid uncured state to transform resin 110 offeedstock line 106 from the first non-rigid uncured state to the rigiduncured state. De-rigidizing mechanism 118 is configured to heat resin110 of feedstock line 106 in the rigid uncured state to transform resin110 of feedstock line 106 from the rigid uncured state to the secondnon-rigid uncured state. The preceding subject matter of this paragraphcharacterizes example 3 of the present disclosure, wherein example 3also includes the subject matter according to example 1 or 2, above.

When rigidizing mechanism 112 withdraws heat from resin 110 of feedstockline 106 to transform it to the rigid uncured state, rigidizingmechanism 112 cools resin 110 to a sufficient degree that its shearmodulus, or rigidity, is sufficiently high for feed mechanism 126 tooperatively advance feedstock line 106 into and through delivery guide116 without undesirably soiling, gumming up, or damaging feed mechanism126 and delivery guide 116. In some examples, rigidizing mechanism 112may be described as freezing resin 110 and/or feedstock line 106. Then,to reverse the rigidity of resin 110 and feedstock line 106,de-rigidizing mechanism 118 heats resin 110 to transform it to thesecond non-rigid uncured state for operative deposition by deliveryguide 116 along print path 114.

Rigidizing mechanism 112 and de-rigidizing mechanism 118 may take anysuitable configuration and utilize any suitable mechanism forwithdrawing heat and applying heat, respectively. For example,rigidizing mechanism 112 may utilize a refrigeration cycle to withdrawheat from resin 110. Additionally or alternatively, rigidizing mechanism112 may utilize a cold fluid that is passed over and contacts feedstockline 106 to withdraw heat from resin 110. In some examples,de-rigidizing mechanism 118 may be or include a resistive heater, aninductive heater, or a radiative heater, such as operatively coupled toor positioned within delivery guide 116, such as at or adjacent to wherefeedstock line 106 exits delivery guide 116. Additionally oralternatively, de-rigidizing mechanism 118 may include or utilize alaser or a heated fluid stream to heat resin 110. In some examples,curing mechanism 120 may additionally serve as de-rigidizing mechanism118. Other examples of rigidizing mechanism 112 and de-rigidizingmechanism 118 also are within the scope of the present disclosure andmay be incorporated into system 100.

Referring generally to FIG. 1 and particularly to FIG. 2, feed mechanism126 is configured to push feedstock line 106 through delivery guide 116.The preceding subject matter of this paragraph characterizes example 4of the present disclosure, wherein example 4 also includes the subjectmatter according to any one of examples 1 to 3, above.

Feed mechanism 126 facilitates the advancement of feedstock line 106into, through, and out of delivery guide 116. By being positioned topush feedstock line 106 though delivery guide 116, it is upstream of theexit of delivery guide 116 and thus is positioned out of the way of themovement of delivery guide 116 and deposition of feedstock line 106along print path 114.

Referring generally to FIG. 1 and particularly to FIG. 2, feed mechanism126 comprises opposing rollers or belts 128, configured to engageopposite sides of feedstock line 106 and to selectively rotate to pushfeedstock line 106 through delivery guide 116. The preceding subjectmatter of this paragraph characterizes example 5 of the presentdisclosure, wherein example 5 also includes the subject matter accordingto example 4, above.

Opposing rollers or belts 128, when selectively rotated, act tofrictionally engage feedstock line 106, thereby feeding it betweenopposing rollers or belts 128 and pushing it into and through deliveryguide 116. Feed mechanism 126 additionally or alternatively may compriseother pinch mechanisms configured to push feedstock line 106 throughdelivery guide 116.

Referring generally to FIG. 1 and particularly to FIG. 2, system 100further comprises control system 130 that comprises at least one sensor132, configured to sense at least one physical characteristic associatedwith feedstock line 106. Control system 130 is configured to activelycontrol at least one of rigidizing mechanism 112, feed mechanism 126,de-rigidizing mechanism 118, or curing mechanism 120, based at least inpart on at least the one physical characteristic associated withfeedstock line 106. The preceding subject matter of this paragraphcharacterizes example 6 of the present disclosure, wherein example 6also includes the subject matter according to any one of examples 1 to5, above.

By sensing at least one physical characteristic associated withfeedstock line 106 and actively controlling rigidizing mechanism 112,feed mechanism 126, de-rigidizing mechanism 118, and/or curing mechanism120 based on at least one physical characteristic associated withfeedstock line 106, system 100 may in real time control the rigidity offeedstock line 106, the feed rate of feedstock line 106, and the curerate of feedstock line 106.

Illustrative, non-exclusive examples of physical characteristicsassociated with feedstock line 106 that may be sensed by at least onesensor 132 include rigidity, stiffness, flexibility, hardness,viscosity, temperature, degree of cure, size, volume fractions, andshape.

In FIG. 2, communication between control system 130 and variouscomponents of system 100 is schematically represented by lightningbolts. Such communication may be wired and/or wireless in nature.

Referring generally to FIG. 1 and particularly to FIG. 2, control system130 is configured to actively control rigidizing mechanism 112, based atleast in part on at least the one physical characteristic, associatedwith feedstock line 106, to control rigidity of resin 110 in the rigiduncured state. The preceding subject matter of this paragraphcharacterizes example 7 of the present disclosure, wherein example 7also includes the subject matter according to example 6, above.

By actively controlling rigidizing mechanism 112 based on at least onephysical characteristic of feedstock line 106, the rigidity of feedstockline 106 in the rigid uncured state may be controlled to ensure thatfeedstock line 106 is sufficiently rigid to be operatively advanced byfeed mechanism 126 into and through delivery guide 116.

Referring generally to FIG. 1 and particularly to FIG. 2, control system130 is configured to actively control feed mechanism 126, based at leastin part on at least the one physical characteristic, associated withfeedstock line 106, to control a feed rate of feedstock line 106. Thepreceding subject matter of this paragraph characterizes example 8 ofthe present disclosure, wherein example 8 also includes the subjectmatter according to example 6 or 7, above.

By actively controlling feed mechanism 126 based at least on onephysical characteristic of feedstock line 106, the feed rate offeedstock line 106 may be controlled, such as to ensure that rigidizingmechanism 112 has ample time to suitably rigidize feedstock line 106and/or so that de-rigidizing mechanism 118 has ample time to suitablyde-rigidize feedstock line 106.

Referring generally to FIG. 1 and particularly to FIG. 2, control system130 is configured to actively control de-rigidizing mechanism 118, basedat least in part on at least the one physical characteristic, associatedwith feedstock line 106, to control rigidity of resin 110 in the secondnon-rigid uncured state. The preceding subject matter of this paragraphcharacterizes example 9 of the present disclosure, wherein example 9also includes the subject matter according to any one of examples 6 to8, above.

By actively controlling de-rigidizing mechanism 118 based at least onone physical characteristic of feedstock line 106, the second non-rigiduncured state of feedstock line 106 may be controlled to ensure asufficient flexibility of feedstock line 106 for operative deposition bydelivery guide 116 along print path 114. In addition, activelycontrolling de-rigidizing mechanism 118 ensures wetting, or adhesion,between two adjacent layers of feedstock line 106, when a length offeedstock line 106 is being deposited against a prior-deposited lengthof feedstock line 106.

Referring generally to FIG. 1 and particularly to FIG. 2, control system130 is configured to actively control curing mechanism 120, based atleast in part on at least the one physical characteristic, associatedwith feedstock line 106, to control a cure rate of resin 110 offeedstock line 106. The preceding subject matter of this paragraphcharacterizes example 10 of the present disclosure, wherein example 10also includes the subject matter according to any one of examples 6 to9, above.

By actively controlling curing mechanism 120 based at least on onephysical characteristic of feedstock line 106, the intensity or power ofcuring energy may be controlled to ensure that a desired degree of cureor cure rate is imparted to feedstock line 106 as object 102 is beingmanufactured by system 100.

Referring generally to FIG. 1 and particularly to FIG. 2, system 100further comprises surface 134 and drive assembly 136. Print path 114 isstationary relative to surface 134. Drive assembly 136 is configured tooperatively and selectively move at least one of delivery guide 116 orsurface 134 relative to each other to additively manufacture object 102.The preceding subject matter of this paragraph characterizes example 11of the present disclosure, wherein example 11 also includes the subjectmatter according to any one of examples 1 to 10, above.

Drive assembly 136 facilitates the relative movement between deliveryguide 116 and surface 134 so that object 102 is manufactured fromfeedstock line 106 as it is deposited via delivery guide 116.

Drive assembly 136 may take any suitable form, such that delivery guide116 and surface 134 may be operatively moved relative to each other inthree dimensions for additive manufacturing of object 102. In someexamples, drive assembly 136 may be a robotic arm, and delivery guide116 may be described as an end effector of the robotic arm. Driveassembly 136 may provide for relative movement between delivery guide116 and surface 134 in any multiple degrees of freedom, including, forexample, orthogonally in three dimensions relative to another, in threedimensions with at least three degrees of freedom relative to another,in three dimensions with at least six degrees of freedom relative toanother, in three dimensions with at least nine degrees of freedomrelative to another, and/or in three dimensions with at least twelvedegrees of freedom relative to another.

Referring generally to FIG. 1 and particularly to FIG. 2, system 100further comprises print-path heater 138, configured to heat print path114 ahead of delivery guide 116 as delivery guide 116 deposits feedstockline 106 along print path 114. The preceding subject matter of thisparagraph characterizes example 12 of the present disclosure, whereinexample 12 also includes the subject matter according to any one ofexamples 1 to 11, above.

By heating print path 114 ahead of delivery guide 116 as delivery guide116 deposits feedstock line 106 along print path 114, print-path heater138 prepares the surface against which feedstock line 106 is deposited.For example, when feedstock line 106 is being deposited against a priorlength of feedstock line 106 that has already been cured, or at leastpartially cured, by curing mechanism 120, heating of the prior length offeedstock line 106 facilitates wetting and adhesion between the twolayers of feedstock line 106.

In some examples, print-path heater 138 may utilize induction heatingand/or resistive heating, for example, with print-path heater 138inductively and/or electrically coupled with elongate fibers 108 withinfeedstock line 106. Additionally or alternatively, print-path heater 138may comprise a radiative heater and/or a laser to heat print path 114.

Referring generally to FIG. 1 and particularly to FIG. 2, system 100further comprises deposited-feedstock-line heater 140, configured toheat feedstock line 106 after feedstock line 106 is deposited bydelivery guide 116. The preceding subject matter of this paragraphcharacterizes example 13 of the present disclosure, wherein example 13also includes the subject matter according to any one of examples 1 to12, above.

By heating feedstock line 106 after it has been deposited by deliveryguide 116, deposited-feedstock-line heater 140 suitably preparesfeedstock line 106, which has already been deposited, for subsequentdeposition and adhesion of feedstock line 106 against itself. Forexample, when a length of feedstock line 106 is cured, or at leastpartially cured, by curing mechanism 120, subsequent or simultaneousheating of the length of feedstock line 106 may facilitate adhesionbetween a subsequent layer of feedstock line 106 deposited against thelength of feedstock line 106. In addition, heating feedstock line 106after it has been deposited by delivery guide 116 may increase thedegree of cure of feedstock line 106 and may be used to control curekinetics or cure rate of resin 110 of feedstock line 106.

In some examples, deposited-feedstock-line heater 140 may utilizeinduction heating and/or resistive heating, for example, withdeposited-feedstock-line heater 140 inductively and/or electricallycoupled with elongate fibers 108 within feedstock line 106. Additionallyor alternatively, deposited-feedstock-line heater 140 may comprise aradiative heater and/or a laser to heat feedstock line 106.

Referring generally to FIGS. 1 and 2 and particularly to FIG. 3, method200 of additively manufacturing object 102 is disclosed. Method 200comprises (block 202) applying resin 110 in a first non-rigid uncuredstate to elongate fibers 108 to create feedstock line 106. Feedstockline 106 comprises elongate fibers 108, at least partially encapsulatedin resin 110. Method 200 also comprises (block 204) transforming resin110 of feedstock line 106 from the first non-rigid uncured state to arigid uncured state. Feedstock line 106 and resin 110 are more rigidwhen resin 110 is in the rigid uncured state than when resin 110 is inthe first non-rigid uncured state. Method 200 further comprises (block206) introducing feedstock line 106 into delivery guide 116 with resin110 of feedstock line 106 in the rigid uncured state. Method 200additionally comprises (block 208) transforming resin 110 of feedstockline 106 from the rigid uncured state to a second non-rigid uncuredstate as feedstock line 106 passes through delivery guide 116 or asfeedstock line 106 exits delivery guide 116. Feedstock line 106 andresin 110 are less rigid when resin 110 is in the second non-rigiduncured state than when resin 110 is in the rigid uncured state. Method200 also comprises (block 210) depositing feedstock line 106 along printpath 114, with resin 110 of feedstock line 106 in the second non-rigiduncured state, using delivery guide 116. Method 200 further comprises(block 212) at least partially curing resin 110 of feedstock line 106after feedstock line 106 is deposited by delivery guide 116 along printpath 114. The preceding subject matter of this paragraph characterizesexample 14 of the present disclosure.

Method 200 therefore may be implemented to manufacture object 102 from afiber reinforced composite material that is created from resin 110 andelongate fibers 108 while object 102 is being manufactured. Moreover,method 200 may be implemented to manufacture object 102 with elongatefibers 108 being oriented in desired and/or predetermined orientationsthroughout object 102, such as to define desired properties of object102. In addition, because resin 110 is uncured when applied to elongatefibers 108 to create feedstock line 106, the first non-rigid uncuredstate of feedstock line 106 comprises resin 110 in a viscous condition.If permitted to remain in such a viscous, tacky, or sticky condition,resin 110 of feedstock line 106 would be difficult to introduce intodelivery guide 116, for example, potentially gumming up delivery guide116 or buckling, kinking, or even breaking elongate fibers 108.Accordingly, transforming resin 110 to the rigid uncured statefacilitates the introduction of feedstock line 106 into and the passageof feedstock line 106 through delivery guide 116, without elongatefibers 108 buckling, breaking, or otherwise becoming damaged, andwithout resin 110 soiling an associated system (e.g., system 100herein). Subsequently transforming resin 110 from the rigid uncuredstate to the second non-rigid uncured state as feedstock line 106 passesthrough delivery guide 116 or as feedstock line 106 exits delivery guide116 results in feedstock line 106 being sufficiently flexible tooperatively be deposited in three dimensions by delivery guide 116 toadditively manufacture object 102. Depending on the properties offeedstock line 106, in some implementations of method 200, it may bebeneficial to transform feedstock line 106 to the second non-rigid curedstate as it passes through delivery guide 116. In other implementationsof method 200, it may be beneficial to transform feedstock line 106 tothe second non-rigid uncured state as it exits delivery guide 116.Finally, at least partially curing resin 110 from the second non-rigiduncured state to an at least partially cured state, enables curing ofobject 102 as it is being manufactured, or in situ.

Referring generally to FIGS. 1 and 2 and particularly to FIG. 3,according to method 200, feedstock line 106 in the first non-rigiduncured state has a shear modulus less than or equal to 0.1 GPa.Feedstock line 106 in the rigid uncured state has a shear modulusgreater than 0.1 GPa. Feedstock line 106 in the second non-rigid uncuredstate has a shear modulus less than or equal to 0.1 GPa. The precedingsubject matter of this paragraph characterizes example 15 of the presentdisclosure, wherein example 15 also includes the subject matteraccording to example 14, above.

With 0.1 GPa as a threshold shear modulus, or rigidity, feedstock line106, when rigidized by rigidizing mechanism 112, is sufficiently rigidto be introduced into delivery guide 116 without elongate fibers 108buckling, breaking, or otherwise becoming damaged. Moreover, by whenhaving a shear modulus below 0.1 GPa, feedstock line 106 may bedeposited along a circuitous print path, e.g., print path 114 withcurves in two or three dimensions. However, other threshold values ofshear modulus may be utilized, such as based on the stiffness ofelongate fibers 108, the number of elongate fibers 108 in acorresponding tow, a shape of feedstock line 106, a diameter offeedstock line 106, properties of resin 110, etc.

Referring generally to FIGS. 1 and 2 and particularly to FIG. 3,according to method 200, (block 204) transforming resin 110 of feedstockline 106 from the first non-rigid uncured state to the rigid uncuredstate comprises (block 214) withdrawing heat from resin 110 of feedstockline 106 in the first non-rigid uncured state. Also, (block 208)transforming resin 110 of feedstock line 106 from the rigid uncuredstate to the second non-rigid uncured state as feedstock line 106 passesthrough delivery guide 116 or as feedstock line 106 exits delivery guide116 comprises (block 216) heating resin 110 of feedstock line 106 in therigid uncured state. The preceding subject matter of this paragraphcharacterizes example 16 of the present disclosure, wherein example 16also includes the subject matter according to example 14 or 15, above.

Withdrawing heat from resin 110 of feedstock line 106 to transform it tothe rigid uncured state cools resin 110 to a sufficient degree that itsshear modulus, or rigidity, is sufficiently high for feedstock line 106to be introduced into delivery guide 116 without elongate fibers 108buckling, breaking, or otherwise becoming damaged. In someimplementations of method 200, withdrawing heat from resin 110 may bedescribed as freezing resin 110. Then, to reverse the rigidity of resin110 and feedstock line 106, heating resin 110 to transform it to thesecond non-rigid uncured state facilitates the operative deposition offeedstock line 106 by delivery guide 116 along print path 114.

Referring generally to FIGS. 1 and 2 and particularly to FIG. 3,according to method 200, (block 206) introducing feedstock line 106 intodelivery guide 116 with resin 110 of feedstock line 106 in the rigiduncured state comprises (block 218) pushing feedstock line 106 intodelivery guide 116 with resin 110 of feedstock line 106 in the rigiduncured state. The preceding subject matter of this paragraphcharacterizes example 17 of the present disclosure, wherein example 17also includes the subject matter according to any one of examples 14 to16, above.

By pushing feedstock line 106 into delivery guide 116, the feedmechanism (e.g., feed mechanism 126) of an associated additivemanufacturing system (e.g., system 100 herein) may be positionedupstream of delivery guide 116, and thus out of the way of deliveryguide 116 to operatively move relative to print path 114.

Referring generally to FIGS. 1 and 2 and particularly to FIG. 3,according to method 200, (block 218) pushing feedstock line 106 intodelivery guide 116 is performed by opposing rollers or belts 128 thatengage opposite sides of feedstock line 106 and selectively rotate topush feedstock line 106 through delivery guide 116. The precedingsubject matter of this paragraph characterizes example 18 of the presentdisclosure, wherein example 18 also includes the subject matteraccording to example 17, above.

Opposing rollers or belts 128, when selectively rotated, act tofrictionally engage feedstock line 106, thereby feeding it betweenopposing rollers or belts 128 and pushing it into and through deliveryguide 116.

Referring generally to FIGS. 1 and 2 and particularly to FIG. 3, method200 further comprises (block 220) sensing at least one physicalcharacteristic associated with feedstock line 106. Method 200 alsocomprises, responsive to (block 220) sensing at least the one physicalcharacteristic associated with feedstock line 106, (block 222) activelycontrolling at least one of (block 204) transforming resin 110 offeedstock line 106 from the first non-rigid uncured state to the rigiduncured state, (block 206) introducing feedstock line 106 into deliveryguide 116 with resin 110 of feedstock line 106 in the rigid uncuredstate, (block 208) transforming resin 110 of feedstock line 106 from therigid uncured state to the second non-rigid uncured state as feedstockline 106 passes through delivery guide 116 or as feedstock line 106exits delivery guide 116, or (block 212) at least partially curing resin110 of feedstock line 106 after feedstock line 106 is deposited bydelivery guide 116 along print path 114. The preceding subject matter ofthis paragraph characterizes example 19 of the present disclosure,wherein example 19 also includes the subject matter according to any oneof examples 14 to 18, above.

By sensing at least one physical characteristic associated withfeedstock line 106, an implementation of method 200 may in real timecontrol the rigidity of feedstock line 106, the feed rate of feedstockline 106, and the cure rate of feedstock line 106.

Referring generally to FIGS. 1 and 2 and particularly to FIG. 3,according to method 200, (block 222) actively controlling (block 204)transforming resin 110 of feedstock line 106 from the first non-rigiduncured state to the rigid uncured state comprises (block 224)controlling rigidity of resin 110 in the rigid uncured state. Thepreceding subject matter of this paragraph characterizes example 20 ofthe present disclosure, wherein example 20 also includes the subjectmatter according to example 19, above.

By actively controlling transforming resin 110 from the first non-rigiduncured state to the rigid uncured state, the rigidity of feedstock line106 in the rigid uncured state may be controlled to ensure thatfeedstock line 106 is sufficiently rigid to be operatively introducedinto and advanced through delivery guide 116.

Referring generally to FIGS. 1 and 2 and particularly to FIG. 3,according to method 200, (block 222) actively controlling (block 206)introducing feedstock line 106 into delivery guide 116 with resin 110 offeedstock line 106 in the rigid uncured state comprises (block 226)controlling a feed rate of feedstock line 106. The preceding subjectmatter of this paragraph characterizes example 21 of the presentdisclosure, wherein example 21 also includes the subject matteraccording to example 19 or 20, above.

By actively controlling introducing feedstock line 106 into deliveryguide 116, the feed rate of feedstock line 106 may be controlled, suchas to ensure that there is ample time to suitably rigidize feedstockline 106 prior to its introduction into delivery guide 116 and/or ampletime to suitably de-rigidize feedstock line 106 prior to its operativedeposition along print path 114 by delivery guide 116.

Referring generally to FIGS. 1 and 2 and particularly to FIG. 3,according to method 200, (block 222) actively controlling (block 208)transforming resin 110 of feedstock line 106 from the rigid uncuredstate to the second non-rigid uncured state as feedstock line 106 passesthrough delivery guide 116 or as feedstock line 106 exits delivery guide116 comprises (block 228) controlling rigidity of resin 110 in thesecond non-rigid uncured state. The preceding subject matter of thisparagraph characterizes example 22 of the present disclosure, whereinexample 22 also includes the subject matter according to any one ofexamples 19 to 21, above.

By actively controlling transforming resin 110 from the rigid uncuredstate to the second non-rigid uncured state, the second non-rigiduncured state of feedstock line 106 may be controlled to ensure asufficient flexibility of feedstock line 106 for operative deposition bydelivery guide 116 along print path 114.

Referring generally to FIGS. 1 and 2 and particularly to FIG. 3,according to method 200, (block 222) actively controlling (block 212) atleast partially curing resin 110 of feedstock line 106 after feedstockline 106 is deposited by delivery guide 116 along print path 114comprises (block 230) controlling a cure rate of resin 110 of feedstockline 106. The preceding subject matter of this paragraph characterizesexample 23 of the present disclosure, wherein example 23 also includesthe subject matter according to any one of examples 19 to 22, above.

By actively controlling at least partially curing resin 110, the curerate that is imparted to feedstock line 106 as object 102 is beingmanufactured may be controlled.

Referring generally to FIGS. 1 and 2 and particularly to FIG. 3, method200 further comprises (block 232) heating print path 114 ahead ofdelivery guide 116 as delivery guide 116 deposits feedstock line 106along print path 114. The preceding subject matter of this paragraphcharacterizes example 24 of the present disclosure, wherein example 24also includes the subject matter according to any one of examples 14 to23, above.

By heating print path 114 ahead of delivery guide 116 as delivery guide116 deposits feedstock line 106 along print path 114, the surfaceagainst which feedstock line 106 is deposited is suitably prepared. Forexample, when feedstock line 106 is being deposited against a priorlength of feedstock line 106 that has already been cured, or at leastpartially cured, heating of the prior length of feedstock line 106facilitates wetting and adhesion between the two layers of feedstockline 106.

Referring generally to FIGS. 1 and 2 and particularly to FIG. 3, method200 further comprises (block 234) heating feedstock line 106 afterfeedstock line 106 is deposited by delivery guide 116 along print path114. The preceding subject matter of this paragraph characterizesexample 25 of the present disclosure, wherein example 25 also includesthe subject matter according to any one of examples 14 to 24, above.

By heating feedstock line 106 after it has been deposited by deliveryguide 116, feedstock line 106, which has been deposited, is suitablyprepared for subsequent deposition and adhesion of feedstock line 106against itself. For example, when a length of feedstock line 106 iscured, or at least partially cured, subsequent or simultaneous heatingof the length of feedstock line 106 may facilitate adhesion between asubsequent layer of feedstock line 106 deposited against the length offeedstock line 106.

Referring generally to FIGS. 1 and 2 and particularly to FIG. 3,according to method 200, (block 202) applying resin 110 in the firstnon-rigid uncured state to elongate fibers 108 to create feedstock line106 comprises applying resin 110 in the first non-rigid uncured state toelongate fibers 108 below a threshold temperature to create feedstockline 106. Also, applying resin 110 in the first non-rigid uncured stateto elongate fibers 108 below the threshold temperature to createfeedstock line 106 (block 204) transforms resin 110 of feedstock line106 from the first non-rigid uncured state to the rigid uncured state.The preceding subject matter of this paragraph characterizes example 26of the present disclosure, wherein example 26 also includes the subjectmatter according to any one of examples 14 to 25, above.

By applying resin 110 to elongate fibers 108 that are below a thresholdtemperature, elongate fibers 108 act as a cold thermal mass, or heatsink, to withdraw heat from resin 110 and thereby transform resin 110 tothe rigid uncured state. The threshold temperature is a function of theproperties of resin 110 and the desired rigidity of resin 110 in therigid uncured state.

Examples of the present disclosure may be described in the context ofaircraft manufacturing and service method 1100 as shown in FIG. 4 andaircraft 1102 as shown in FIG. 5. During pre-production, illustrativemethod 1100 may include specification and design (block 1104) ofaircraft 1102 and material procurement (block 1106). During production,component and subassembly manufacturing (block 1108) and systemintegration (block 1110) of aircraft 1102 may take place. Thereafter,aircraft 1102 may go through certification and delivery (block 1112) tobe placed in service (block 1114). While in service, aircraft 1102 maybe scheduled for routine maintenance and service (block 1116). Routinemaintenance and service may include modification, reconfiguration,refurbishment, etc. of one or more systems of aircraft 1102.

Each of the processes of illustrative method 1100 may be performed orcarried out by a system integrator, a third party, and/or an operator(e.g., a customer). For the purposes of this description, a systemintegrator may include, without limitation, any number of aircraftmanufacturers and major-system subcontractors; a third party mayinclude, without limitation, any number of vendors, subcontractors, andsuppliers; and an operator may be an airline, leasing company, militaryentity, service organization, and so on.

As shown in FIG. 5, aircraft 1102 produced by illustrative method 1100may include airframe 1118 with a plurality of high-level systems 1120and interior 1122. Examples of high-level systems 1120 include one ormore of propulsion system 1124, electrical system 1126, hydraulic system1128, and environmental system 1130. Any number of other systems may beincluded. Although an aerospace example is shown, the principlesdisclosed herein may be applied to other industries, such as theautomotive industry. Accordingly, in addition to aircraft 1102, theprinciples disclosed herein may apply to other vehicles, e.g., landvehicles, marine vehicles, space vehicles, etc.

Apparatus(es) and method(s) shown or described herein may be employedduring any one or more of the stages of the manufacturing and servicemethod 1100. For example, components or subassemblies corresponding tocomponent and subassembly manufacturing (block 1108) may be fabricatedor manufactured in a manner similar to components or subassembliesproduced while aircraft 1102 is in service (block 1114). Also, one ormore examples of the apparatus(es), method(s), or combination thereofmay be utilized during production stages 1108 and 1110, for example, bysubstantially expediting assembly of or reducing the cost of aircraft1102. Similarly, one or more examples of the apparatus or methodrealizations, or a combination thereof, may be utilized, for example andwithout limitation, while aircraft 1102 is in service (block 1114)and/or during maintenance and service (block 1116).

Different examples of the apparatus(es) and method(s) disclosed hereininclude a variety of components, features, and functionalities. Itshould be understood that the various examples of the apparatus(es) andmethod(s) disclosed herein may include any of the components, features,and functionalities of any of the other examples of the apparatus(es)and method(s) disclosed herein in any combination, and all of suchpossibilities are intended to be within the scope of the presentdisclosure.

Many modifications of examples set forth herein will come to mind to oneskilled in the art to which the present disclosure pertains having thebenefit of the teachings presented in the foregoing descriptions and theassociated drawings.

Therefore, it is to be understood that the present disclosure is not tobe limited to the specific examples illustrated and that modificationsand other examples are intended to be included within the scope of theappended claims. Moreover, although the foregoing description and theassociated drawings describe examples of the present disclosure in thecontext of certain illustrative combinations of elements and/orfunctions, it should be appreciated that different combinations ofelements and/or functions may be provided by alternative implementationswithout departing from the scope of the appended claims. Accordingly,parenthetical reference numerals in the appended claims are presentedfor illustrative purposes only and are not intended to limit the scopeof the claimed subject matter to the specific examples provided in thepresent disclosure.

The invention claimed is:
 1. A method of additively manufacturing anobject, the method comprising steps of: applying a resin in a firstnon-rigid uncured state to elongate fibers to create a feedstock line,wherein the feedstock line comprises the elongate fibers at leastpartially encapsulated in the resin; transforming the resin of thefeedstock line from the first non-rigid uncured state to a rigid uncuredstate using a rigidizing mechanism, wherein the feedstock line and theresin are more rigid when the resin is in the rigid uncured state thanwhen the resin is in the first non-rigid uncured state, and wherein theresin of the feedstock line is transformed to the rigid uncured stateprior to the feedstock line being pushed into a delivery guide by a feedmechanism; introducing the feedstock line into the delivery guide withthe resin of the feedstock line in the rigid uncured state by saidpushing of the feedstock line into the delivery guide using the feedmechanism; transforming the resin of the feedstock line from the rigiduncured state to a second non-rigid uncured state using a de-rigidizingmechanism as the feedstock line passes through the delivery guide or asthe feedstock line exits the delivery guide, wherein the feedstock lineand the resin are less rigid when the resin is in the second non-rigiduncured state than when the resin is in the rigid uncured state; sensingat least one physical characteristic associated with rigidity of theresin of the feedstock line within the delivery guide, the at least onephysical characteristic being selected from rigidity, stiffness,flexibility, hardness, and viscosity; responsive to the step of sensingthe at least one physical characteristic associated with rigidity of theresin of the feedstock line within the delivery guide, activelycontrolling, in real time, (i) the rigidizing mechanism to control thestep of transforming the resin of the feedstock line from the firstnon-rigid uncured state to the rigid uncured state, and (ii) the feedmechanism to control a feed rate of the feedstock line, being pushedinto the delivery guide; depositing the feedstock line along a printpath, with the resin of the feedstock line in the second non-rigiduncured state, using the delivery guide, wherein the step of activelycontrolling, in real time, the rigidizing mechanism and the feedmechanism ensures that the feedstock line is sufficiently flexible sothat said deposition of the feedstock line by the delivery guide alongthe print path may be performed operatively; and at least partiallycuring the resin of the feedstock line after the feedstock line isdeposited by the delivery guide along the print path.
 2. The methodaccording to claim 1, wherein: the feedstock line in the first non-rigiduncured state has a shear modulus less than or equal to 0.1 GPa; thefeedstock line in the rigid uncured state has a shear modulus greaterthan 0.1 GPa; and the feedstock line in the second non-rigid uncuredstate has a shear modulus less than or equal to 0.1 GPa.
 3. The methodaccording to claim 1, wherein: the step of transforming the resin of thefeedstock line from the first non-rigid uncured state to the rigiduncured state comprises withdrawing heat from the resin of the feedstockline in the first non-rigid uncured state; and the step of transformingthe resin of the feedstock line from the rigid uncured state to thesecond non-rigid uncured state as the feedstock line passes through thedelivery guide or as the feedstock line exits the delivery guidecomprises heating the resin of the feedstock line in the rigid uncuredstate.
 4. The method according to claim 1, further comprising heatingthe print path ahead of the delivery guide as the delivery guidedeposits the feedstock line along the print path.
 5. The methodaccording to claim 1, wherein: the step of applying the resin in thefirst non-rigid uncured state to the elongate fibers to create thefeedstock line comprises applying the resin in the first non-rigiduncured state to the elongate fibers with the elongate fibers below athreshold temperature, thereby resulting in the step of transforming theresin of the feedstock line from the first non-rigid uncured state tothe rigid uncured state.
 6. The method according to claim 1 wherein thepushing the feedstock line into the delivery guide using the feedmechanism is performed by opposing rollers or belts that engage oppositesides of the feedstock line and selectively rotate to push the feedstockline through the delivery guide.
 7. The method according to claim 1,further comprising heating the feedstock line after the feedstock lineis deposited by the delivery guide along the print path.
 8. The methodaccording to claim 1, wherein the step of actively controlling, in realtime, the rigidizing mechanism and the feed mechanism further comprisesactively controlling, in real time, (iii) the de-rigidizing mechanism tocontrol the step of transforming the resin of the feedstock line fromthe rigid uncured state to the second non-rigid uncured state as thefeedstock line passes through the delivery guide or as the feedstockline exits the delivery guide.
 9. The method according to claim 1,wherein the step of at least partially curing the resin of the feedstockline after the feedstock line is deposited by the delivery guide alongthe print path is actively controlled, in real time, responsive to thestep of sensing the at least one physical characteristic associated withrigidity of the resin of the feedstock line within the delivery guide,to control a cure rate of the resin of the feedstock line deposited bythe delivery guide along the print path.
 10. A method of additivelymanufacturing an object, the method comprising steps of: applying aresin in a first non-rigid uncured state to elongate fibers to create afeedstock line, wherein the feedstock line comprises the elongate fibersat least partially encapsulated in the resin; transforming the resin ofthe feedstock line from the first non-rigid uncured state to a rigiduncured state using a rigidizing mechanism, wherein the feedstock lineand the resin are more rigid when the resin is in the rigid uncuredstate than when the resin is in the first non-rigid uncured state, andwherein the resin of the feedstock line is transformed to the rigiduncured state prior to the feedstock line being pushed into a deliveryguide by a feed mechanism; introducing the feedstock line into thedelivery guide with the resin of the feedstock line in the rigid uncuredstate by said pushing of the feedstock line into the delivery guideusing the feed mechanism; transforming the resin of the feedstock linefrom the rigid uncured state to a second non-rigid uncured state using ade-rigidizing mechanism as the feedstock line passes through thedelivery guide or as the feedstock line exits the delivery guide,wherein the feedstock line and the resin are less rigid when the resinis in the second non-rigid uncured state than when the resin is in therigid uncured state; sensing at least one physical characteristicassociated with rigidity of the resin of the feedstock line within thedelivery guide, the at least one physical characteristic being selectedfrom rigidity, stiffness, flexibility, hardness, and viscosity;responsive to the step of sensing the at least one physicalcharacteristic associated with rigidity of the resin of the feedstockline within the delivery guide, actively controlling, in real time, (i)the de-rigidizing mechanism to control the step of transforming theresin of the feedstock line from the rigid uncured state to the secondnon-rigid uncured state as the feedstock line passes through thedelivery guide or as the feedstock line exits the delivery guide and(ii) the feed mechanism to control a feed rate of the feedstock linebeing pushed into the delivery guide; depositing the feedstock linealong a print path, with the resin of the feedstock line in the secondnon-rigid uncured state, using the delivery guide, wherein the step ofactively controlling, in real time, the de-rigidizing mechanism and thefeed mechanism ensures that the feedstock line is sufficiently flexibleso that said deposition of the feedstock line by the delivery guidealong the print path may be performed operatively; and at leastpartially curing the resin of the feedstock line after the feedstockline is deposited by the delivery guide along the print path.
 11. Themethod according to claim 10, wherein: the feedstock line in the firstnon-rigid uncured state has a shear modulus less than or equal to 0.1GPa; the feedstock line in the rigid uncured state has a shear modulusgreater than 0.1 GPa; and the feedstock line in the second non-rigiduncured state has a shear modulus less than or equal to 0.1 GPa.
 12. Themethod according to claim 10, wherein: the step of transforming theresin of the feedstock line from the first non-rigid uncured state tothe rigid uncured state comprises withdrawing heat from the resin of thefeedstock line in the first non-rigid uncured state; and the step oftransforming the resin of the feedstock line from the rigid uncuredstate to the second non-rigid uncured state as the feedstock line passesthrough the delivery guide or as the feedstock line exits the deliveryguide comprises heating the resin of the feedstock line in the rigiduncured state.
 13. The method according to claim 10, further comprisingheating the print path ahead of the delivery guide as the delivery guidedeposits the feedstock line along the print path.
 14. The methodaccording to claim 10, wherein: the step of applying the resin in thefirst non-rigid uncured state to the elongate fibers to create thefeedstock line comprises applying the resin in the first non-rigiduncured state to the elongate fibers with the elongate fibers below athreshold temperature, thereby resulting in the step of transforming theresin of the feedstock line from the first non-rigid uncured state tothe rigid uncured state.
 15. The method according to claim 10, whereinthe pushing the feedstock line into the delivery guide using the feedmechanism is performed by opposing rollers or belts that engage oppositesides of the feedstock line and selectively rotate to push the feedstockline through the delivery guide.
 16. The method according to claim 10,further comprising heating the feedstock line after the feedstock lineis deposited by the delivery guide along the print path.
 17. The methodaccording to claim 10, wherein the step of at least partially curing theresin of the feedstock line after the feedstock line is deposited by thedelivery guide along the print path is actively controlled, in realtime, responsive to the step of sensing the at least one physicalcharacteristic associated with rigidity of the resin of the feedstockline within the delivery guide, to control a cure rate of the resin ofthe feedstock line deposited by the delivery guide along the print path.18. A method of additively manufacturing an object, the methodcomprising steps of: applying a resin in a first non-rigid uncured stateto elongate fibers to create a feedstock line, wherein the feedstockline comprises the elongate fibers at least partially encapsulated inthe resin; transforming the resin of the feedstock line from the firstnon-rigid uncured state to a rigid uncured state using a rigidizingmechanism, wherein the feedstock line and the resin are more rigid whenthe resin is in the rigid uncured state than when the resin is in thefirst non-rigid uncured state, and wherein the resin of the feedstockline is transformed to the rigid uncured state prior to the feedstockline being pushed into a delivery guide by a feed mechanism; introducingthe feedstock line into the delivery guide with the resin of thefeedstock line in the rigid uncured state by said pushing of thefeedstock line into the delivery guide using the feed mechanism;transforming the resin of the feedstock line from the rigid uncuredstate to a second non-rigid uncured state using a de-rigidizingmechanism as the feedstock line passes through the delivery guide or asthe feedstock line exits the delivery guide, wherein the feedstock lineand the resin are less rigid when the resin is in the second non-rigiduncured state than when the resin is in the rigid uncured state; sensingat least one physical characteristic associated with rigidity of theresin of the feedstock line within the delivery guide, the at least onephysical characteristic being selected from rigidity, stiffness,flexibility, hardness, and viscosity; responsive to the step of sensingthe at least one physical characteristic associated with rigidity of theresin of the feedstock line within the delivery guide, activelycontrolling, in real time, (i) the rigidizing mechanism to control thestep of transforming the resin of the feedstock line from the firstnon-rigid uncured state to the rigid uncured state, (ii) thede-rigidizing mechanism to control the step of transforming the resin ofthe feedstock line from the rigid uncured state to the second non-rigiduncured state as the feedstock line passes through the delivery guide oras the feedstock line exits the delivery guide, and (iii) the feedmechanism to control a feed rate of the feedstock line being pushed intothe delivery guide; depositing the feedstock line along a print path,with the resin of the feedstock line in the second non-rigid uncuredstate, using the delivery guide, wherein the step of activelycontrolling ensures that the feedstock line is sufficiently flexible sothat said deposition of the feedstock line by the delivery guide alongthe print path may be performed operatively; and at least partiallycuring the resin of the feedstock line after the feedstock line isdeposited by the delivery guide along the print path, wherein the stepof at least partially curing the resin of the feedstock line after thefeedstock line is deposited by the delivery guide along the print pathis actively controlled, in real time, responsive to the step of sensingthe at least one physical characteristic associated with rigidity of theresin of the feedstock line within the delivery guide, to control a curerate of the resin of the feedstock line deposited by the delivery guidealong the print path.
 19. The method according to claim 18, wherein: thefeedstock line in the first non-rigid uncured state has a shear modulusless than or equal to 0.1 GPa; the feedstock line in the rigid uncuredstate has a shear modulus greater than 0.1 GPa; and the feedstock linein the second non-rigid uncured state has a shear modulus less than orequal to 0.1 GPa.
 20. The method according to claim 18, wherein: thestep of transforming the resin of the feedstock line from the firstnon-rigid uncured state to the rigid uncured state comprises withdrawingheat from the resin of the feedstock line in the first non-rigid uncuredstate; and the step of transforming the resin of the feedstock line fromthe rigid uncured state to the second non-rigid uncured state as thefeedstock line passes through the delivery guide or as the feedstockline exits the delivery guide comprises heating the resin of thefeedstock line in the rigid uncured state.
 21. The method according toclaim 18, further comprising heating the print path ahead of thedelivery guide as the delivery guide deposits the feedstock line alongthe print path.
 22. The method according to claim 18, wherein: the stepof applying the resin in the first non-rigid uncured state to theelongate fibers to create the feedstock line comprises applying theresin in the first non-rigid uncured state to the elongate fibers withthe elongate fibers below a threshold temperature, thereby resulting inthe step of transforming the resin of the feedstock line from the firstnon-rigid uncured state to the rigid uncured state.
 23. The methodaccording to claim 18, wherein pushing the feedstock line into thedelivery guide using the feed mechanism is performed by opposing rollersor belts that engage opposite sides of the feedstock line andselectively rotate to push the feedstock line through the deliveryguide.
 24. The method according to claim 18, further comprising heatingthe feedstock line after the feedstock line is deposited by the deliveryguide along the print path.